Method of removing foil shield from cable

ABSTRACT

A method of removing a foil shield from a cable includes positioning the cable proximate a heating source, monitoring a characteristic of the cable or the heating source with at least one sensor, heating the foil shield in a designated area to weaken the foil shield, and removing an outer insulation of the cable and the foil shield.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 16/359,323, filed Mar. 20, 2019.

FIELD OF THE INVENTION

The present invention is directed to a process or method to weaken thefoil shield on shielded cable using heating. In particular, the presentinvention is directed to a process or method to weaken the foil shieldon shielded cable using induction heating.

BACKGROUND OF THE INVENTION

Certain cable types, such as those used for electric and hybridvehicles, have a foil shield that must be removed to prepare the cablefor termination. The foil consists of a Poly-Ethylene Terephthalate(PET) plastic substrate with aluminum deposited on the bottom. The foilis typically very difficult to remove because it is very thin (0.03 mmthick) and tear-resistant (due to the PET substrate). In addition, thebraid shield, which is directly beneath the foil, must not be damagedwhen the foil is removed.

Current foil removal methods include manual processes, blade processes,and laser processes. Manual processes are slow and costly. Bladeprocesses are typically very expensive and often damage the braidshield. Laser processes are expensive as costly equipment is required.

It would, therefore, be beneficial to provide a cost effective andefficient process or method to remove the foil without damaging thebraid shield or the other components of the cable. In addition, it wouldbe advantageous to provide a system or method of removing the foil whichcan be uses as a stand-alone process or method or as an integratedmethod in a machine which performs other functions on the cable.

SUMMARY OF THE INVENTION

The invention is directed to a process or method that uses heating, suchas, but not limited to, induction heating, to weaken the foil in thearea where it will be removed. The heating generates heat in thealuminum component of the foil, which heats the Poly-EthyleneTerephthalate (PET) plastic component of the foil and either melts it orvaporizes it. The foil can be heated either through the outerinsulation, or the outer insulation can be pre-cut to allow thevaporized PET to escape. When the PET plastic melts beneath the outerinsulation, it sticks to the outer insulation as it cools. This allowsfor the foil and outer insulation to be removed in one step.

An embodiment is directed to a method of removing a foil shield from acable, the method comprising: positioning the cable proximate aninduction heating source; heating the foil shield in a designated areato weaken the foil shield; and removing an outer insulation of the cableand the foil shield after the foil shield has been heated.

An embodiment is directed to a method of removing a foil shield from acable, the method comprising: positioning the cable proximate aninduction heating source; heating the foil shield by induction heatingin a designated area to weaken the foil shield; removing the inductionheating source; cutting an outer insulation of the cable in thedesignated area; and removing the outer insulation of the cable and thefoil shield from the designated area.

An embodiment is directed to a method of removing a foil shield from acable, the method comprising: positioning the cable proximate aninduction heating source; exposing a portion of the foil shield in thedesignated area by cutting the outer insulation; heating the foil shieldby induction heating in a designated area to weaken the foil shield;removing the induction heating source; and removing the outer insulationof the cable and the foil shield from the designated area.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a longitudinal cross-section of an illustrative high voltagecable which has a foil shield provided therein.

FIG. 2 is a perspective view of the cable with a portion of the outerinsulation removed to show the foil shield.

FIG. 3 is a diagrammatic view of the longitudinal cross-section of theillustrative cable with an induction coil extending around thecircumference of a section of the cable.

FIG. 4 is a diagrammatic end view of the illustrative cable with theinduction coil extending around the circumference of a section of thecable, as shown in FIG. 3 .

FIG. 5 is a diagrammatic view of the longitudinal cross-section of theillustrative cable with the induction coil extending around thecircumference of a section of the cable, the induction coil applyingheat to the cable.

FIG. 6 is a diagrammatic end view of the illustrative cable with theinduction coil extending around the circumference of a section of thecable, the induction coil applying heat to the cable, as shown in FIG. 5.

FIG. 7 is a diagrammatic view of the longitudinal cross-section of theillustrative cable illustrating the heat effected area of the cable.

FIG. 8 is a diagrammatic view of the longitudinal cross-section of theillustrative cable illustrating stripping blades in engagement with theouter insulation of the cable.

FIG. 9 is a diagrammatic view of the longitudinal cross-section of theillustrative cable illustrating the stripping blades removing the outerinsulation and the foil shield of the cable.

FIG. 10 is a diagrammatic view of the longitudinal cross-section of theillustrative cable illustrating an alternate step in which the strippingblades are in engagement with the outer insulation of the cable prior tothe induction coil applying heat to the cable.

FIG. 11 is a diagrammatic view of the longitudinal cross-section of theillustrative cable of FIG. 10 illustrating the stripping bladespartially removing the outer insulation and exposing a portion of thefoil shield of the cable.

FIG. 12 is a diagrammatic view of the longitudinal cross-section of theillustrative cable with an induction coil extending around thecircumference of a section of the cable of FIG. 10 .

FIG. 13 is a diagrammatic end view of the illustrative cable with theinduction coil extending around the circumference of a section of thecable, the induction coil applying heat to the cable.

FIG. 14 is a diagrammatic view of the longitudinal cross-section of theillustrative cable of FIG. 13 , illustrating the heat effected area ofthe cable.

FIG. 15 is a diagrammatic view of the longitudinal cross-section of theillustrative cable of FIG. 14 , illustrating stripping blades inengagement with the outer insulation of the cable.

FIG. 16 is a diagrammatic view of the longitudinal cross-section of theillustrative cable of FIG. 15 , illustrating the stripping bladesremoving the outer insulation and the foil shield of the cable.

FIG. 17 is a diagrammatic view illustrating the induction coilintegrated into a machine that performs other functions of the cable.

FIG. 18 is a simplified view of a system used to control the machine ofFIG. 17 for performing methods according to embodiments of the presentdisclosure.

FIG. 19 is a diagrammatic view of the longitudinal cross-section of theillustrative cable with the induction coil applying heat to the cable ina periodic manner.

FIGS. 20A, 20B and 20C are diagrammatic views of a longitudinalcross-section of the illustrative cable being fed through the inductioncoil so as to apply heat over a longer area of the cable.

FIGS. 21A and 21B are diagrammatic views of the longitudinalcross-section of the illustrative cable with the induction coilextending around a circumference of the cable at a targeted location inwhich the insulation has previously been removed.

FIG. 22 is a diagrammatic view of the longitudinal cross-section of theillustrative cable with the induction coil extending around acircumference of the cable wherein a thermal imagining device isutilized for monitoring at least one characteristic of the cable duringheating.

FIGS. 23A, 23B and 23C are diagrammatic views of the longitudinalcross-section of the illustrative cable in which the induction coil ispositioned around overlapping portions of the foil shield of the cable.

FIGS. 24A, 24B and 24C are diagrammatic views of the longitudinalcross-section of the illustrative cable in which the induction coil andthe thermal imaging device are used to detect foil scrap or unwantedmaterial on the cable.

DETAILED DESCRIPTION OF THE INVENTION

The description of illustrative embodiments according to principles ofthe present invention is intended to be read in connection with theaccompanying drawings, which are to be considered part of the entirewritten description. In the description of embodiments of the inventiondisclosed herein, any reference to direction or orientation is merelyintended for convenience of description and is not intended in any wayto limit the scope of the present invention. Relative terms such as“lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,”“down,” “top” and “bottom” as well as derivative thereof (e.g.,“horizontally,” “downwardly,” “upwardly,” etc.) should be construed torefer to the orientation as then described or as shown in the drawingunder discussion. These relative terms are for convenience ofdescription only and do not require that the apparatus be constructed oroperated in a particular orientation unless explicitly indicated assuch. Terms such as “attached,” “affixed,” “connected,” “coupled,”“interconnected,” and similar refer to a relationship wherein structuresare secured or attached to one another either directly or indirectlythrough intervening structures, as well as both movable or rigidattachments or relationships, unless expressly described otherwise.

Moreover, the features and benefits of the invention are illustrated byreference to the preferred embodiments. Accordingly, the inventionexpressly should not be limited to such embodiments illustrating somepossible non-limiting combination of features that may exist alone or inother combinations of features, the scope of the invention being definedby the claims appended hereto.

Referring to FIGS. 1 and 2 , an illustrative embodiment of an electricalcable 10 is shown. In the embodiment shown, the cable 10 is a highvoltage cable, but other cables can be used. The cable 10 includes aconductor 12 which conducts the electrical current. Inner insulation 14extends circumferentially around the conductor 12. A braid shield 16extends circumferentially around the inner insulation 14. A foil shield18 extends circumferentially around the braid shield 16. Outerinsulation 20 extends circumferentially around the foil shield 18. Inthe illustrative embodiment shown, the foil shield 18 has an aluminumcomponent and a Poly-Ethylene Terephthalate (PET) plastic component,however, other components may be used.

In order to terminate the cable 10 as required for particularapplications, the foil shield 18 must be removed to allow fortermination of the conductor 12 of the cable 10. However, the foilshield 18 is typically very difficult to remove because it is very thin(for example, 0.03 mm thick) and tear-resistant. In addition, the braidshield 16, which is directly beneath the foil shield 18, must not bedamaged when the foil shied 18 is removed. The method as described andclaimed herein allows the foil shield 18 to be efficiently and costeffectively removed without damaging the braid shield 16 or othercomponents of the cable 10.

Referring to FIGS. 3 through 9 , the cable 10 is positioned in anopening 30 of an induction coil 32, as shown in FIGS. 3 and 4 .Alternatively, the opening 30 of the induction coil 32 is positionedover the cable 10. The induction coil 32 is positioned over an area 34of the cable 10 in which the foil shield 18 and the outer conductor 20are to be removed or stripped from the cable 10 to expose the braidshield 16. The opening 30 of the induction coil 32 is dimensioned to fitover the outer insulation 20 without engaging the outer insulation 20.

With the induction coil 32 properly positioned, the induction coil 32 ispowered, causing the induction coil to generate a rapidly alternatingmagnetic field which causes heat to be generated in the foil shield 18,as represented by 36 in FIGS. 5 and 6 . In the embodiment shown in FIGS.5 and 6 , the foil shield 18 is heated through the outer insulation 20.The induction heating generates heat in the aluminum component of thefoil shield 18 in the designated or affected area 34, which heats theplastic component of the foil shield 18 in the designated or affectedarea above a melting point of the plastic component. As the plasticcomponent is melted, the plastic component pools together and formsvoids in which only the aluminum component remains. As the aluminumcomponent is thin and has little shear or tensile strength, the poolingof the plastic component and the forming of voids weakens the foilshield 18 in the designated or affected area 34.

The power is supplied to the induction coil 32 for a specified amount oftime based on the application. The frequency of the induction coil 32may be varied to control the depth of heating or skin depth, forexample, higher frequency allows the depth of the induction heating tobe controlled such that the penetration of the induction heating isshallow, whereby the induction heating does not penetrate into the braidshield 16 or the conductor 12. Whereas, a lower frequency allowsinduction heating to more deeply penetrate into the braid shield 16 orthe conductor 12.

As represented in FIG. 7 , after the specified time, the heat generatedby the induction coil 32 is stopped and the induction coil 32 is removedfrom proximate the designated or affected area 34 of the cable 10. Withthe heat removed, the melted pooled plastic component is allowed tocool. As the plastic component is cooled, the plastic component and thefoil shield 18 in the designated or affected area 34 sticks or adheresto the outer insulation 20. This allows for the foil shield 18 and outerinsulation 20 to act as one piece in the designated or affected area 34.

As best shown in FIG. 8 , the stripping blades 40 are then moved intoengagement with the outer insulation 20 at one end of the designated oraffected area 34 of the cable 10. Alternatively, the designated oraffected area 34 of the cable 10 is moved into position relative to thestripping blades 40. As this occurs, the sharp edges of the strippingblades 40 pierce or cut the outer insulation 20. The depth of thestripping blades 40 is controlled to ensure that the stripping blades 40do not contact the braid shield 16. In various embodiments, thestripping blades 40 may contact the foil shield 18, while in otherembodiments, the stripping blades 40 may not contact the foil shield 18.

With the stripping blades 40 properly positioned relative to the outerinsulation 20, the stripping blades 40 are moved in an axial directionrelative to the cable 10 toward a free end 42 of the cable 10, asrepresented in FIG. 9 . As the stripping blades 40 are in engagementwith the outer insulation 20, the movement of the stripping blades 40 inthe axial direction causes the cut portion 44 of the outer insulation 20to be moved axially relative to the cable 10 simultaneously with thestripping blades 40.

As the foil shield 18 is adhered to the outer insulation 20 in thedesignated or affected area 34, the movement of the outer insulation 20in the cut portion 44 causes the foil shield 18 in the cut portion 44 tobe moved axially relative to the cable 10 simultaneously with thestripping blades 40. As this occurs, the weakened foil shield 18 in thedesignated or affected area 34 tears and is released from the foilshield 18 in the non-cut portion 46 of the cable 10.

Referring to FIGS. 10 through 16 , an alternate illustrative method orprocess of removing the foil shield 18 from the cable 10 is shown. Inthis illustrative embodiment the stripping blades 40 are moved intoposition relative to designated or affected area 34 proximate the freeend 42 of the cable 10. Alternatively, the designated or affected area34 of the cable 10 is moved into position relative to the strippingblades 40.

The stripping blades 40 are moved into engagement with the outerinsulation 20, as shown in FIG. 10 . As this occurs, the sharp edges ofthe stripping blades 40 pierce or cut the outer insulation 20. The depthof the stripping blades 40 is controlled to ensure that the strippingblades 40 do not contact the foil shield 18 or the braid shield 16.

With the stripping blades 40 properly positioned relative to the outerinsulation 20, the stripping blades 40 are moved a controlled distancein an axial direction relative to the cable 10 toward a free end 42 ofthe cable 10 to form an opening or split 50 in the outer insulation 20of the cable 10, as represented in FIG. 11 , thereby exposing a portionof the foil shield 18 in the designated or affected area 34 through theopening 50.

With a portion of the foil shield 18 in the designated or affected area34 exposed, the stripping blades 40 are retracted and the cable 10 ispositioned in an opening 30 of an induction coil 32, as shown in FIG. 12. Alternatively, the opening 30 of the induction coil 32 is positionedover the cable 10. The induction coil 32 is positioned over an area 34of the cable 10 in which the foil shield 18 and the outer conductor 20are to be removed or stripped from the cable 10 to expose the braidshield 16. The opening 30 of the induction coil 32 is dimensioned to fitover the outer insulation 20 without engaging the outer insulation 20.

With the induction coil 32 properly positioned, the induction coil 32 ispowered, causing the induction coil to generate a rapidly alternatingmagnetic field which causes heat to be generated in the foil shield 18,as represented by 36 in FIG. 13 . In the embodiment shown in FIG. 13 ,the foil shield 18 is heated through the opening 50. The inductionheating generates heat in the aluminum component 51 of the foil shield18 in the designated or affected area 34, which heats the plasticcomponent of the foil shield 18 in the designated or affected area abovea melting point of the plastic component. As the plastic component ismelted, the plastic component exposed in the opening 50 is vaporized andescapes, while the plastic component proximate the opening 50 beneaththe outer insulation 20 melts. As only the aluminum 51 component remainsin the portion of the designated or affected area 34 which is exposed tothe opening 50, the aluminum component 51 is thin and has little shearor tensile strength, causing the foil shield 18 to be weak in thedesignated or affected area 34 which is exposed to the opening 50.

The power is supplied to the induction coil 32 for a specified amount oftime based on the application. The frequency of the induction coil 32may be varied to control the depth of heating or skin depth. Forexample, a higher frequency allows the depth of the induction heating tobe controlled such that the penetration of the induction heating isshallow, whereby the induction heating does not penetrate into the braidshield 16 or the conductor 12. Whereas, a lower frequency allowsinduction heating to more deeply penetrate into the braid shield 16 orthe conductor 12.

As represented in FIG. 14 , after the specified time, the heat generatedby the induction coil 32 is stopped and the induction coil 32 is removedfrom proximate the designated or affected area 34 of the cable 10. Withthe heat removed, the melted plastic component below the outerinsulation 20 is allowed to cool. As the plastic component is cooled,the plastic component and the foil shield 18 in the designated oraffected area 34 beneath the outer insulation 20 sticks or adheres tothe outer insulation 20. This allows for the foil shield 18 and outerinsulation 20 to act as one piece in the designated or affected area 34.

As best shown in FIG. 15 , the stripping blades 40 are again moved intoengagement with the outer insulation 20 at one end of the designated oraffected area 34 of the cable 10. Alternatively, the designated oraffected area 34 of the cable 10 is moved into position relative to thestripping blades 40. As this occurs, the sharp edges of the strippingblades 40 pierce or cut the outer insulation 20. The depth of thestripping blades 40 is controlled to ensure that the stripping blades 40do not contact the braid shield 16. In various embodiments, thestripping blades 40 may contact the foil shield 18, while in otherembodiments, the stripping blades 40 may not contact the foil shield 18.

With the stripping blades 40 properly positioned relative to the outerinsulation 20, the stripping blades 40 are moved in an axial directionrelative to the cable 10 toward a free end 42 of the cable 10, asrepresented in FIG. 16 . As the stripping blades 40 are in engagementwith the outer insulation 20, the movement of the stripping blades 40 inthe axial direction causes the cut portion 44 of the outer insulation 20to be moved axially relative to the cable 10 simultaneously with thestripping blades 40.

As the foil shield 18 is adhered to the outer insulation 20 in thedesignated or affected area 34, the movement of the outer insulation 20in the cut portion 44 causes the foil shield 18 in the cut portion 44 tobe moved axially relative to the cable 10 simultaneously with thestripping blades 40. As this occurs, the weakened foil shield 18 in thedesignated or affected area 34 tears and is released from the foilshield 18 in the non-cut portion 46 of the cable 10.

The method described with respect to the embodiment shown in FIGS. 1through 16 may be integrated in a machine 70 which performs otherfunctions on the cable 10, as shown in FIG. 17 . The machine 70 mayinclude, but is not limited to the induction coil 32, feed wheels 72 andcutting blades 40. Representative machines 70 include, but are notlimited to, cut-to-length machines, cut-and-strip machines or leadmakers. The cable 10 may feed from a spool (not shown). The machine 70will pause feeding the cable 10 in specified areas where the inductioncoil 32 operates and where the outer jacket 20 and foil shield 18 isstripped.

The invention is directed to a process or method that uses inductionheating to weaken the foil in the area where it will be removed. Theinduction heating generates heat in the aluminum component of the foil,which heats the plastic component of the foil and either melts it orvaporizes it. The foil can be heated either through the outerinsulation, or the outer insulation can be pre-cut to allow thevaporized plastic component to escape. When the plastic component meltsbeneath the outer insulation, it sticks to the outer insulation as itcools. This allows for the foil and outer insulation to be removed inone step. The method allows different materials or components anddifferent cable sizes, configurations and diameters to be accommodatedby changing variables including power, frequency, heat applied time, andcoil geometry. The method also allows for different heating elements andheating processes and is not limited to induction coils and inductionheating.

Methods according to embodiments of the present invention may be carriedout wholly or in part by one or more automated control systemsimplementing and/or controlling the above-described components, as wellas additional hardware and software features. For example, referringgenerally to FIG. 18 , an exemplary control system 100 useful forperforming the operations of the embodiments of the present disclosureis shown. The control system 100 may be under fully-automated control,or fully or partially controlled via one or more user input devices 105(e.g., touch screen/buttons/keyboards, etc.). The control system 100includes at least one processor 110, such as a digital microprocessorresponsive to instructions stored on a memory device 120 for performingthe methods or operations described herein. The processor 110 isoperatively coupled to the induction coil 32, and/or to a power supplythereof for selectively powering the coil under voltage and/or currentcontrol. The system 100 may further include a current and/or frequencymonitor or sensor 130, which may be operative with the processor 110 tomonitor and/or control the frequency and current in or through theinduction coil 32.

The system 100, and more specifically the processor 110, may control theoperation of the feed wheels 72 of the machine 70 for selectivelyfeeding the cable through the machine. Likewise, the system 100 maycomprise one or more actuators 140 (e.g., a linear actuator) operativelyattached to the induction coil 32 for selectively moving the coilrelative to a cable. In one embodiment, the one or more actuators 140may be multi-directional, having the ability to vary not only thelongitudinal position of the induction coil 32 along a length of acable, but also the radial or lateral distance between the cable and theinduction coil, further promoting the ability to accurately control thegeneration of heat in predetermined areas of the cable.

The system 100 further comprises a temperature sensing device and/orimaging device, such as a thermal imaging device, and more specificallyan infrared (IR) temperature sensor and/or camera 150, by way of exampleonly. In other embodiments, the system 100 may comprise separatetemperature sensing devices and imaging devices. Further, the imagingdevice 150 may be optical, such as a digital camera or video capturingdevice without departing from the scope of the present disclosure. Thethermal imaging device 150 may be mounted to the induction coil 32, orto another portion of the system 70 suitable for achieving desiredoperation.

The system 100, including the processor 110 operative with associatedinstructions pre-stored on the memory device 120 enables severaladditional modes of operations to those described above with respect tothe proceeding figures. By way of example, using the current and/orfrequency monitor 130, as well as predetermined values stored on thememory device 120, the processor 110 is operative to determine orestimate a characteristic, such as a size of the cable under heating,and automatically adjust various operating parameters according to thisdetermination. The system 100 may vary heating times, periodic cyclingparameters, frequency, voltage and/or current associated with theoperation of the induction coil 32 according to a detected cable sizefor achieving optimal operation. These parameters may be pre-stored inthe memory device 120 such that, upon a determination by the processor110 as to the relevant characteristics of the cable 10, the function ofthe coil 32 may be automatically controlled without the need for furtheruser input.

Referring generally to FIG. 19 , operating the induction coil 32 underprecise computer control enables the implementation of thermal cyclingoperations, including a plurality of powered or heating cycles 191 ofthe induction coil 32, each followed by a subsequent depowered orcooling period 192 of the induction coil. This on/off cycling isbeneficial to accurately generate a predetermined amount of heat in thecable 10, for example, in the foil shield 18. An exemplary thermalcycle, represented in the figure by a square wave function 193, mayinclude powering the induction coil 32 for 0.5 seconds, and de-poweringfor 0.5 seconds. This may be performed for a predetermined plurality ofcycles, for example four cycles, to achieve desired heatingcharacteristics (e.g., temperature and uniformity) of the cable 10.

With reference to FIGS. 20A, 20B and 20C, the machine 70, alone or incombination with the one or more actuators 140 associated with theinduction coil 32, is operative to move the cable 10 longitudinallythrough the coil in the indicated direction while heating the foilshield 18 along an elongated zone. More specifically, FIG. 20B mayrepresent the designated or affected area 34 of a stationary inductioncoil 32 and cable 10, while FIG. 20C is indicative of a process whereinthe cable 10 is translated during heating, increasing a length of thedesignated or affected area 34. It has been determined that the outerinsulation 20 of the cable 10 is often easier to remove by selectivelyadhering the foil shield 18 in a specific area of the cable, therebyincreasing its rigidity and thus decreasing its resistance to tearing,breaking or cutting. Thus, by feeding the cable 10 and/or translatingthe induction coil 32 to a desired location, selective removal of theouter insulation 20 and/or foil shield 18 is further enabled. Thisapplication is specifically useful for magnetic wire applications,wherein very thin insulation layers or coatings more easily selectivelyremoved via the above-described process.

Systems and methods according to embodiments of the present disclosuremay also be operative to initially remove the outer insulation 20 of acable 10 entirely, or in a selective area, and subsequently apply heatwith the induction coil 32 to affect the foil directly. This may includeweakening of the foil, or vaporization thereof. FIGS. 21A and 21Billustrate the induction coil 32 arranged about the cable 10 in an areawhich has been pre-stripped of its outer insulation by, for example, thestripping blades 40. Once removed, a portion of the cable 10, such asthe foil shield 18, may be heated in the designated or affected area 34in the absence of the outer insulation therebetween. In one embodiment,induction heating is performed to melt a tin plating on select areas ofthe braid shield for fusing the braid strands together as the tin cools.Likewise, embodiments of the present disclosure are operative to performa heat treatment process to anneal copper strands of the cable 10,making them easier to cut in a desired or predetermined location. Thesemethods are beneficial for containment and cleanliness. Morespecifically, by fusing strands of the foil shield 18 in front of adesignated cutoff area, a solidified area of waste material can beformed, enabling easier and more efficient processing, such as removal,handling and/or disposal.

Referring now to FIG. 22 , the thermal imaging device or IR camera 150may be used for several process monitoring objectives. For example, thethermal imaging device 150 may be fixed within the system 70 and adaptedto monitor the change in temperature in the cable 10 during the heatingprocess, and alter the function of the induction coil 32 accordingly. Inthis way, the system 100 is enabled to automatically heat the cable 10properly without needing inputs from the user. In addition to thisclosed-loop control of heating, the use of thermal detection devicesimproves quality control, ensuring proper temperature and/or timecharacteristics are achieved during a cable processing operation. Thethermal imaging device 150 and the processor 110 may be configured todifferentiate between cable sizes base on heating characteristics.Similar detection processes may be accomplished by the frequency and/orcurrent monitors 130. Specifically, monitoring the frequency and/orcurrent through the coil 32 can also be used to determine the sizeand/or type of the cable within the coil. This may be achieved bycomparing measured values to predetermined values associating currentand/or frequency with a characteristic of the cable. These predeterminedvalues may be stored on the memory device 120. Frequency may also bemonitored to determine the general presence or absence of a cable withinthe coil.

FIGS. 23A-23C illustrate the bonding of overlapped areas 18′ of the foilshield 18 using inductive heating. Specifically, as shown in FIG. 23A,the foil shield 18 may comprise areas of overlap 18′ over its length.These areas of overlap create difficulties in ensuring the entirety ofthe foil shield 18 is removed. By specifically targeting heating withthe induction coil 32 in these problematic areas, as illustrated inFIGS. 23B and 23C, the foil shield 18 is ensured to be more completelyremoved in the resulting affected areas 34, improving process qualityand efficiency.

Referring now to FIGS. 24A-24C, embodiments of the present disclosureutilize inductive heating to make conductive scrap easier to detect. Asillustrated, the inductive coil 32 may be used to generate a relativelysmall amount of heat sufficient enough to make the scrap visible to thethermal imaging device 150. If, for example, there is a piece of braidor foil scrap 18″ remaining on the cable, the thermal imaging device 150and/or the processor 110 may detect its heat signature and identify itas a potential issue, further improving process quality and control.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the spirit and scope of theinvention as defined in the accompanying claims. One skilled in the artwill appreciate that the invention may be used with many modificationsof structure, arrangement, proportions, sizes, materials and componentsand otherwise used in the practice of the invention, which areparticularly adapted to specific environments and operative requirementswithout departing from the principles of the present invention. Thepresently disclosed embodiments are therefore to be considered in allrespects as illustrative and not restrictive, the scope of the inventionbeing defined by the appended claims, and not limited to the foregoingdescription or embodiments.

What is claimed is:
 1. A method of removing a foil shield from a cable,the method comprising: positioning the cable proximate an inductionheating source; heating the foil shield in a designated area to weakenthe foil shield; determining a physical characteristic of the cable withat least one sensor; altering an operating characteristic of theinduction heating source according to the determined physicalcharacteristic; removing an outer insulation of the cable; and removingthe foil shield.
 2. The method as recited in claim 1, wherein the stepof removing the outer insulation of the cable is performed before thesteps of positioning the cable and heating the foil shield.
 3. Themethod as recited in claim 1, further comprising the step of moving apredetermined length of the cable through the induction heating sourceduring the step of heating the foil shield.
 4. The method as recited inclaim 3, wherein the step of removing an outer insulation of the cableand removing the foil shield are performed after the foil shield hasbeen heated over the predetermined length, the method further comprisingthe step of cooling a plastic component of the foil shield to adhere tothe outer insulation in the designated area prior to the outerinsulation of the cable and the foil shield being removed from thedesignated area.
 5. The method as recited in claim 1, wherein the stepof determining a physical characteristic of the cable includes the stepsof: with a current monitor, measuring the current in an induction coilof the induction heating source during the heating step; and comparingthe measured current to a predetermined set of values associated with aphysical characteristic of a cable.
 6. The method as recited in claim 1,wherein the step of determining a physical characteristic of the cableincludes the step of capturing at least one thermal image of the cable.7. The method as recited in claim 1, wherein the step of determining aphysical characteristic of the cable includes the steps of: with afrequency monitor, measuring an operating frequency of an induction coilof the induction heating source; and comparing the operating frequencyto a predetermined set of values associated with a physicalcharacteristic of a cable.
 8. The method as recited in claim 7, whereinthe physical characteristic includes the presence or absence of a cablewithin the induction coil.
 9. The method as recited in claim 1, whereinthe step of heating the foil shield is performed in a periodic mannerincluding a plurality of alternating heating and cooling periods. 10.The method as recited in claim 1, wherein the step of positioning thecable proximate an induction heating source includes positioning theinduction heating source over overlapping areas of the foil.
 11. Themethod as recited in claim 1, wherein the step of removing the outerinsulation of the cable includes engaging the outer insulation with atleast one stripping blade.
 12. The method as recited in claim 1, whereinthe step of positioning the cable proximate the induction heating sourceincludes positioning the cable through an opening in the inductionheating source.
 13. The method as recited in claim 12, wherein theinduction heating source surrounds the cable.
 14. The method as recitedin claim 1, wherein the steps of removing the outer insulation of thecable and removing the foil shield are performed simultaneously.
 15. Themethod as recited in claim 1, further comprising the step of adheringthe foil shield to the outer insulation of the cable prior to the stepsof removing the outer insulation of the cable and removing the foilshield.
 16. The method as recited in claim 1, wherein the step ofheating the foil shield includes controlling a depth of the heating ofthe cable according to an operating frequency of the induction heatingsource.
 17. A method of removing a foil shield from a cable, the methodcomprising the steps of: positioning the cable proximate an inductionheating source; heating the foil shield in a designated area to weakenthe foil shield; detecting a temperature of the designated area duringthe step of heating the foil shield; controlling a characteristic of theheating step according to the detected temperature; removing an outerinsulation of the cable; and removing the foil shield.
 18. The method asrecited in claim 17, wherein the characteristic of the heating stepincludes at least one of the duration, current, or frequency ofoperation of an induction coil of the induction heating source.
 19. Amethod of removing a foil shield from a cable, the method comprising thesteps of: positioning the cable proximate an induction heating source;heating the foil shield in a designated area to weaken the foil shield;removing an outer insulation of the cable; removing the foil shield;heating a remaining area of cable after the step of removing the foil;capturing a thermal image of the cable; and identifying conductive scrapremaining on the cable.
 20. A method of removing a foil shield from acable, the method comprising the steps of: positioning the cableproximate an induction heating source; heating the foil shield in adesignated area to weaken the foil shield; removing an outer insulationof the cable; removing the foil shield; heating a predetermined area ofa braided shield of the cable for fusing braid strands of the braidedshield together; and cutting the cable in an area proximate thepredetermined area.